B. Driveshaft Yoke, Input/Output Shaft Oil Seal/Trns. Case Rpl.

NOTE:
Refer to the service manual for other oil leak repair procedures that require transfer case disassembly.





1. Inscribe mating marks on the differential companion flange and the flange yoke (Figure 4).

2. Disconnect the driveshaft from the differential (Figure 4).

3. Remove the heat shield from the front driveshaft support (if equipped).

4. Remove the driveshaft support(s) and carefully remove the driveshaft.

5. FOR VEHICLES THAT REQUIRE DRIVESHAFT YOKE REPLACEMENT:

NOTE:
Complete this step on any vehicle that exhibited signs of leakage from the driveshaft yoke.





A. Remove the snap rings that secure the universal joint to the driveshaft (Figure 5).





B. Using Special Tool MB99O84O (or equivalent), press the bearing journal out of one side of the driveshaft (Figure 6).

C. Turn the driveshaft over and press out the opposite bearing journal.

D. Remove and discard the driveshaft yoke and universal joint.

E. Grease the driveshaft journals and the two supplied journal bearings with Mopar Multi-Purpose Grease or equivalent.

F. Install the provided driveshaft yoke and universal joint assembly on the driveshaft.

G. Press one of the supplied journal bearings into the driveshaft using Special Tool MB99O84O or equivalent (Figure 6).

H. Turn the driveshaft over and press in the opposite bearing journal until the snap ring groove is fully visible.

I. Install a snap ring into one of the driveshaft snap ring grooves.

J. Using a brass bar, press the universal joint from the other side until it contacts the snap ring.

K. Install a snap ring in the groove on the other side of the driveshaft.

IMPORTANT:
BOTH snap rings MUST be the same size (thickness).
Four (4) different thickness snap ring pairs have been provided (1.28 mm, 1.31 mm, 1.34 mm, 1.37 mm).





L. With a feeler gauge, measure the clearance between the snap ring and the journal bearing (Figure 7). If the clearance is not between 0.01 - 0.03 mm remove the snap rings and repeat Steps 51 - 5K with the appropriate snap ring pair as necessary.

6. FOR VEHICLES THAT REQUIRE TRANSFER CASE OUTPUT SHAFT OIL SEAL REPLACEMENT:

NOTE:
Only complete this step on vehicles that exhibited signs of leakage from the transfer case output shaft seal.

A. Remove the output shaft oil seal from the transfer case.





B. Using special tools MD998822 and MD998812 (or equivalent), press the new output shaft oil seal (PN MD7OI43O) into the transfer case (Figure 8).

7. FOR VEHICLES THAT REQUIRE TRANSFER CASE REPLACEMENT OR TRANSFER CASE INPUT SHAFT OIL SEAL REPLACEMENT:

NOTE:
Only complete this step on vehicles that require transfer case replacement or on vehicles that exhibit signs of leakage from the input shaft seal.

A. Disconnect the front exhaust pipe from the exhaust manifold.

B. Disconnect the exhaust hanger just in front of the catalytic converter.





C. Remove the six (6) bolts that attach the transfer case to the transaxle (Figure 9).

D. Separate the transfer case from the transaxle (use a plastic hammer if necessary) and remove the transfer case from the transaxle by tilting the case downward.





E. FOR VEHICLES THAT REQUIRE TRANSFER CASE INPUT SHAFT OIL SEAL REPLACEMENT: Remove the transfer case input shaft oil seal and install a new input shaft oil seal (Manual -- PN MD723202 or Automatic -- PN MD731793) using special tools MB998833 and MB990938 (or equivalent) (Figure 10). Lightly coat the new seal with the recommended gear oil.

F. Install the new transfer case assembly (or original transfer case with new input shaft oil seal) (Figure 9). Tighten the six (6) attaching bolts to 52 ft-lbs (70 N.m) (automatic transaxle) or 42 ft-lbs (57.5 N.m) (manual transaxle).

G. Connect the front exhaust hanger.

H. Connect the front exhaust pipe to the exhaust manifold. Tighten the attaching bolts to 36 ft-lbs (50 N.m). Tighten the bracket bolt to 26 ft-lbs (35 N.m).

8. Lightly coat the driveshaft yoke with the recommended gear oil, insert the driveshaft yoke into the transfer case and then install the center driveshaft supports.

9. Install the driveshaft by aligning the mating marks (Figure 4) and then connecting the driveshaft to the differential. Tighten the driveshaft support and driveshaft-to-differential nuts to 22 ft-lbs (29 N.m).

10. Install the heat shield on the front driveshaft support (if equipped).

11. Reinstall the transfer case drain plug (if removed).

12. Fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher).

13. Install the transfer case oil filler plug.

14. Lower the vehicle.